In the fields of high-end manufacturing and scientific research, the precision and reliability of optical components directly determine the performance of equipment. As a technology-driven company deeply rooted in the optical industry, Wuhan Star Optic Technology Co., Ltd. has consistently centered its services on “customized design + precision manufacturing,” providing global clients with comprehensive solutions covering optical lenses, laser optical components, imaging lenses, and more.
This article provides an in-depth overview of our customized optical lens production process, demonstrating our full-chain technical capabilities—from requirement analysis to final product delivery.
The starting point of customized service is a precise understanding of customer requirements. For different application scenarios—such as laser cutting systems, medical endoscopic imaging, or astronomical observation equipment—our technical team utilizes a 3D parameter modeling system to digitally analyze key lens parameters including radius of curvature, center thickness, and surface finish.
For specialized requirements, such as improving the laser damage threshold of collimating and focusing lenses or achieving precise wavelength control in infrared filters, we leverage a 20-year industry database to quickly match relevant historical cases. Combined with material property analysis, our engineers propose optimized solutions to ensure feasibility at the theoretical design stage.
Material quality forms the foundation of optical component performance. Star Optic has established a comprehensive raw material library covering optical glass (SCHOTT, OHARA), crystal materials (calcium fluoride, zinc selenide), and specialty polymers, supported by three key quality-control procedures:
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Spectral Performance Testing
Spectrophotometers verify transmission curves from the ultraviolet to the far-infrared spectrum. -
Homogeneity Control
Interferometers test refractive index uniformity (＜5×10⁻⁶). -
Stress-Level Screening
Polariscopes ensure materials meet laser-grade low-birefringence standards.
The core manufacturing process follows a “CNC shaping + iterative polishing” process chain:
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Ultra-precision turning
High-precision CNC machines achieve aspheric lens surface accuracy with PV values below 0.3 μm. -
Ion beam polishing
For difficult-to-process materials such as visible-light optics and infrared chalcogenide glass, surface roughness is reduced to below Ra 0.5 nm. -
Edge chamfer protection
Diamond grinding wheels create customized edge angles to prevent chipping during assembly.
In right-angle prism processing projects, multi-axis grinding controls angular error within ±3 arcseconds, meeting the strict requirements of satellite-borne spectrometers.
Optical coating is a critical step that gives components their functional properties. The company is equipped with Optorun coating systems from Japan and ion-assisted deposition technology, supporting:
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Anti-reflection coatings
Multi-layer broadband AR coatings achieving reflectivity below 0.2% in the visible spectrum. -
Laser coating systems
High-reflection coatings at 1064 nm capable of withstanding continuous laser loads of 100 MW/cm². -
Special functional coatings
Including dynamic polarization beam-split ratios for beam splitters and optimized phase-delay precision for wave plates.
Quality verification runs throughout the entire production process:
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Surface figure inspection
Zygo laser interferometers measure lens wavefront distortion (λ/10 @ 632.8 nm). -
Dimensional tolerance control
Coordinate measuring machines ensure lens diameter tolerances within ±0.01 mm. -
Environmental testing
Temperature cycling tests from -50°C to 150°C verify the thermal shock resistance of optical windows. -
Functional verification
A laser damage threshold testing platform simulates real operating conditions through pulse testing.
To meet the demand for small-batch, multi-variety production, the company improves service efficiency through three key measures:
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Modular design
Processes such as prism bonding and filter cutting are divided into standardized operational units. -
Intelligent scheduling system
Over 50 interconnected processing machines enable dynamic order scheduling. -
Dedicated logistics solutions
Shock-resistant vacuum packaging ensures safe transportation of delicate components such as high-precision wave plates.
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Industrial laser applications
Custom protective lenses for 3 kW fiber lasers, where optimized coatings extend service life by 300%. -
Biomedical applications
Development of ultra-small-aperture aspheric lens assemblies for endoscopes, achieving 2-megapixel imaging resolution. -
Aerospace applications
Radiation-resistant beam splitters successfully deployed in satellite multispectral imaging systems.
Star Optic consistently adheres to a dual-driven strategy of precision manufacturing and agile service, continuously pushing technological boundaries in optical windows, mirrors, laser components, and other optical products.
From concept design to mass production, our comprehensive industrial chain and deep technical expertise enable us to deliver customized optical solutions that are truly irreplaceable for every client.
For customized solutions or sample testing, please visit our official website or contact our technical team. Professional support will be provided within 24 hours.